Comflex Rubber Expansion Joints Engineering Guide Product Description Technical Data Advice on Application Calculation Criteria

Transcription

1 Comflex Rubber Expansion Joints Engineering Guide Product Description Technical Data Advice on Application Calculation Criteria High Performance Expansion Joints

2 Comflex Rubber Expansion Joints Contents Engineering Guide Suary of Comflex Expansion Joints 3 Bellows Construction Rubber qualities, reinforcing materials and max. application range for various bellows types Material Description 5 Comflex Expansion Joints Tie Bars Restraints Special Parts Flameproof protective covers, deflector sleeve, earth cover, safety, pressure balanced Planning, Installation and Maintenance Instructions 52 for s 39, 5,,, 9,, 51, 53, 5, 55, 5, 5 Installation and Maintenance for all Solid Flanges 5 for s, 2, 5, 59, 3 Flange Bolt Torques (Nm) for s, 2, 5, 59, 3 59 Installation and Maintenance Instructions for 1 Installation Instructions for 0 2 Sealing Profile of the Rubber Bellows 3 Mating Flange Dimensions Additional Comflex Expansion Joints 5 Technical Guides and Data Sheets 2 To order or get further details, call your local contact shown on rear cover or listed at

3 Suary of Comflex Expansion Joints 55 range 00 Overall length () range 00 Overall length () variable Fields of Application Shipbuilding, Industrial Plants, RepairSubstitute range 0 00 Overall length () 0 Fields of Application Power Stations, Coercial Plants, Purification Plants, Pipelines range 00 Overall length () 15 Fields of Application Shipbuilding, Paper Industry, Hydraulic Systems, Power Stations Range Overall length () 1 5 Fields of Application Housing Technology, Motor Technology, Air Conditioning System, Sprinkler System range Overall length () 1 Fields of Application, Housing Technology, Motor Technology Fields of Application Shipbuilding, Housing Technology, Waterworks and Purification Plants range 0 Overall length () 0 00 Fields of Application Shipbuilding, Paper Industry, Material Handling Technology, Media Particles Solution range 0 Overall length () 0 Fields of Application Shipbuilding, Paper Industry, Material Handling Technology, Media Particles Solution range 00 Overall length () 00 Fields of Application Shipbuilding, Paper Industry, Material Handling Technology, Media Particles Solution range 0 00 Overall length () 0 Fields of Application Shipbuilding, Paper Industry, Material Handling Technology, Media Particles Solution 9 51 range Overall length () 0 1 Fields of Application Steel works, Shipbuilding, Plant Construction range 0 Overall length () 01 Fields of Application Housing Technology, Shipbuilding, Plant Construction, Gas Plants Scales Technology range 00 Overall length () Fields of Application Plant Construction, Gas Plants, Housing Technology, Power Stations range 00 Overall length () 1 Fields of Application Chemical Plants range 0 Overall length () 90 Fields of Application Housing Technology, Industrial Plants range 00 Overall length () Fields of Application Industrial Plants, Motor Technology, Sewage Technology range 00 Overall length () variable Fields of Application Drainage Systems for Bridges, Large Buildings range Overall length () all variable Fields of Application Special handformed items, Plant constructionwall seals 53 range 0 Overall length () 1 range Overall length () all variable Fields of Application Plant constructions, Housing Technology, Waterworks and Purification Plants Fields of Application Motor Technology, Sewage Technology, Air Construction, Plant constructionwall seals 5 range 1 Overall length () range Overall length () 1 Fields of Application Hydraulic System Fields of Application Chemical Plants To order or get further details, call your local contact 3shown on rear cover or listed at 3

4 Bellows Construction Core (inner) Bellows design Reinforcing material Cover (outer) Bellows colour code max. pressure max. permissible temperature (bar C) Aramid Special cord redred red Steel cord redredblue NBR Aramid Special cord NBR yellowblue NBR Chloroprene yellow NBR Chloroprene orange NBR Steel cord Chloroprene yellowyellow Hypalon CSM Aramid Special cord Hypalon CSM greenblue Hypalon CSM Hypalon CSM green Chloroprene Chloroprene grey Butyl IIR redblue Butyl IIRD Aramid Special cord redblue Viton FKM Aramid Special cord Chloroprene lilac Viton FKM Aramid Special cord lilacred Viton FKM Aramid Special cord Viton FKM lilaclilac Aramid Special cord SIL 2 Special manufacture for higher pressure and temperature is available on request. Important: Quoted values are max. values. The quoted pressures are valid at C a decrease relative to increasing temperatures. Please contact James Walker Townson for resistance at specific temperatures To order or get further details, call your local contact shown on rear cover or listed at

5 Material Description Abbreviation (colour code) Name Properties Ethylene Good heat resistance and suitable for alkaline waste water, compressed air propylene terpolymer (oil free) and chemicals, weatherresistant, good gas tightness red terpolymer except for hydrocarbon. Temperature range C up to +1 C Not suitable for oils or fatty media. NBR Acryonitrile Oil and fuel quality, also suitable for gases, solvents and fats. butadiene High abrasion resistance. yellow rubber Temperature range C up to +90 C (1 C) Not suitable for steam and hot water. NBR Acryonitrile Oil and fuel quality, also suitable for gases, solvents and fats and butadiene LPG acc. to DIN 52. High abrasion resistance. rubber Temperature range C up to +90 C orange Not suitable for steam and hot water. NBR Acryonitrile Foodstuff quality in accordance with RAL guidelines, good for pulps, butadiene fats, flours, juices and wines. white rubber Temperature range C up to +90 C Hypalon CSM Chloro Chemical resistant quality for acids, bases and lyes. sulfonated Temperature range C up to +1 C polyethylene See resistance lists for specific temperatures. green Neoprene Chloroprene Water quality, weatherresistant, suitable for some small groups of lyes as well as rubber compressed air and lightly oilrelated media. grey Temperature range C up to +90 C SIL Silicone Suitable for diluted hydrochloric acids, animal and herbal oils and fats, rubber Hydraulic fluids (HFDR and HFDS) Temperature range C up to +0 C none Butyl IIR Butyl Good heat resistance, suitable for alkaline waste water, compressed air (oil free), red or blue rubber chemicals and special hydraulic oils, weatherresistant. Temperature range C up to +90 C Drinking water quality in accordance with KTWGuidelines. Butyl IIRD Butyl Good heat resistance, suitable for alkaline waste water, compressed air (oil free), rubber chemicals and special hydraulic oils, weatherresistant. redblue Temperature range C up to +0 C Viton FKM Fluorocarbon Particularly suited to high temperatures. polymer Good resistance to chemicals and oils, combustibles and solvents. lilac Temperature range C up to + C Not suitable for ketones and chlorine. PTFE Polytetrafluoro Resistant to most media. none ethylene Temperature range C up to +2 C Not suitable for alkali metals in molten state and reactionformed amides. The indicated temperatures relate to flexible applications. In rigid applications lower temperatures can be used. For pressure and expansion details please refer to the type descriptions. For chemical resistance please contact James Walker Townson. To order or get further details, call your local contact 5shown on rear cover or listed at 5

6 James Walker Townson Rubber Comflex Expansion Joint 39 TYPE is a handbuilt low corrugated rubber Comflex Expansion Joint and can therefore be customised to fit in any existing gap by virtue of its variable overall length. Design: Low corrugated rubber bellows with reinforcing inserts and builtin packing profile for absorption of the swivel flanges. The expansion joint is selfsealing, no additional gaskets are required. Characteristics for type 39 Bellows colour code Core (inner) Bellows design Reinforcing material Cover (outer) Permissible operating data bar C bar C Electrical resistance bar C Ohm cm Hardness shore A redst Steel cord x 2 0 red 1 90 x 2 0 yellowst NBR Steel cord x 3 0 yellow NBR 90 5 x 3 0 greenst CSM Steel cord CSM 1 90 x 5 green CSM CSM 90 x 5 white NBRwhite 0 5 x 3 0 lilac FKM Aramid Burst pressure > 3 x max. bar Suitable for vacuum up to 0. bar abs., without supporting ring Suitable for vacuum up to 0 bar abs., with supporting ring Vacuum supporting rings James Walker Townson type 39 expansion joints are vacuum resistant. To prevent the expansion joint bellows being drawn together by suction at negative pressure, the insertion of a vacuum supporting ring is necessary for a suction value above 2 m (0. bar abs., % negative pressure). A Flanges: (Design A) Swivel flanges both sides (Design A) with integral rubber profile, so that additional gaskets are not required (selfsealing). The flanges are drilled to DIN PN as standard. Other specifications in accordance with DIN, ASA, BS and special flanges are also available. Flange Material: Standard S 2 JRG2 (RSt 32) zinc plated and yellow passivated. Other materials available on request. Note: For aggressive media please refer to the resistance table. The bellows must not be painted or insulated. Further installation advices in appendix. Accessories: Tie barrestraints See page Deflector sleeve See page Flameproof protective cover See page Earth cover See page 51 To order or get further details, call your local contact shown on rear cover or listed at

7 Application: TYPE For drinking water hot water red For cold and hot water, also with the addition of chemicals for water treatment. Industrial water, acids, lyes, alcohols, esters and ketones. Not suitable for oilrelated media. 39 For the food and beverage industry white Also suitable for oil and fatcontaining foodstuff. 39 For chemical plants green For heavy chemical use. Permissible temperature, working pressure and life expectancy depend on the medium and its concentration in each case. 39 For oil, fuel, gas yellow Application range: Town and natural gas, blast furnace gas, fuel, lube oil, heating oil, cooling water emulsion 39 For chemical plants lilac Particularly for higher thermal duty up to approx. 0 C. The highest permissible load depends on a mixture of temperature, pressure, movement and life expectancy Overall length Bellows ØA Effect. ØD surface cm Flange PN Movement absorption ØPC Ød n s axial lat. ØC Permissible % of indicated movement relative to temperature: up to C ~ 0% up to C ~ 5% up to 90 C ~ 0% Tie bar and flange design see Annex page To order or get further details, call your local contact shown on rear cover or listed at

8 James Walker Townson Rubber Comflex Expansion Joint incorporates a highly flexible convolution with solid rubber flanges. It is characterized by its ability to compensate for high movement and its low inherent resistance. TYPE Design: High corrugated rubber bellows body with reinforcing inserts and integral pressurestrengthened solid rubber flanges, selfsealing, requiring no additional gaskets. Onepiece steel backing flanges, with supporting collar, to ensure the smooth rolling up of the bellows. Application: Cooling water piping in power stations and industrial plant, desalination plants, drinking water supply, shipbuilding and in pumps, turbines and tanks, for the absorption of movements, oscillations, noise and vibrations, as well as being installed as an axial and lateral expansion joint for building settlement. Max. 00 Flange: Standard design acc. to DIN PN, retaining flange in S 2 JRG2 (RSt. 32) hotdip galvanized. Other materials and drillings are possible on request. Overall lengths: The indicated overall lengths are standard lengths and can be altered (multicorrugated design for higher expansion compensation possible). Details for type Bellows identification marking Core Reinforcing material Cover Pressure (max.) bar Temperature (max.) C red redred blue white grey green greenred yellow yellowred yellowyellow lilac lilac Aramid Aramid Aramid Aramid Aramid Glass Fibre Aramid The pressure indication states a max. value which depends on the lengths and nominal widths (see chart page 9 and ) burst pressure > bar. All Comflex Expansion Joints can be delivered with a compensation of potential. Suitable for vacuum up to 0. bar abs., without supporting ring (2m suction height). Suitable for vacuum up to 0 bar abs., with supporting ring (m suction height). The bellows can be manufactured with vulcanized PTFE foil to achieve a higher chemical resistance. On request vacuum rings can be vulcanized in the bellows (no vacuum or medium contact). Flange connections will be manufactured on request in all versions, e.g. PN, PN, PN1, ANSI B 1.5 class 0, ANSI B 1. class 0. The steel retaining flanges will be designed according to the pressure with or without supporting collar. The preloading flanges will be calculated according to the operating pressure (versions see page and 9). To order or get further details, call your local contact shown on rear cover or listed at

9 9 To order or get further details, call your local contact shown on rear cover or listed at Overall length Effective area length Wave inner Thickness of steel flange bar bar bar bar cm 2 Reinforcing material Nylon Aramid at at 13 at at axial + lateral + Expansion Pressure resistance type short length (can be extended and shortened on request) Rubber flange pressure (max.) max. 00

10 To order or get further details, call your local contact shown on rear cover or listed at Overall length Effective area at length Wave inner Thickness of steel flange bar bar bar bar cm 2 Reinforcing material Nylon Aramid at at 13 at at axial + lateral + Expansion Pressure resistance type standard lengths (can be extended on request also twocorrugated) Rubber flange pressure (max.) max. 00

11 Stiffness rate axial for type (average value by full way) Overall length 0 bar N 1 bar N 2,5 bar N bar N bar N bar N Attention: Variations in stiffness rate are possible by material reinforcing or production process change with +%. To order or get further details, call your local contact 11 shown on rear cover or listed at 11

12 Stiffness rate lateral for type (average value by full way) Overall length 0 bar N 1 bar N 2,5 bar N bar N bar N bar N Attention: Variations in stiffness rate are possible by material reinforcing or production process change with +%. To order or get further details, call your local contact shown on rear cover or listed at

13 Restraint: Under pressure the expansion joint bellows produces a reaction force (in the axial direction [effective surface area x operating pressure]), which must be absorbed by the nearest anchorpoints. TYPE For purely lateral or angular movement it is possible, with restraints (see tie bar page ) to relieve the anchorpoints or mounting point connections of the reaction force, so that only the adjusting forces from the extension movement still have to be absorbed. Restraint Design E Hinged arrangement Design F Restraint Design M With external tie bar Design K Pressure balanced expansion joint Important Note: Counter flanges must be designed smooth and without recesses. The bellows must not be insulated or painted. See installation information, page 5. To order or get further details, call your local contact 13 shown on rear cover or listed at 13

14 James Walker Townson Rubber Comflex Expansion Joint 2 2 is a robust, thickwalled rubber Comflex Expansion Joint with integrated corrugation produced by hand winding. TYPE 2 The manufacturing process makes it possible to produce this expansion joint in variable overall lengths and pressure ratings. Design: Synthetic rubber body with various reinforcing inserts and fully strengthened rubber flanges with or without steel insert. The rubber flange is selfsealing so that no additional gasket is required. Details for type 2 Bellows colour code red Core (inner) Bellows design Reinforcing material Cover (outer) Permissible operating data bar C 90 Electrical resistance [Ohm cm] x 2 Hardness shore A 0 redred Aramid yellow NBR 90 5 x 3 0 yellowblue NBR Aramid green CSM CSM 90 x 5 white NBRwhite 0 5 x 3 55 lilac FKM Kevlar 0 5 Burst pressure > bar, Suitable for vacuum 0. bar absolute, full vacuum with supporting ring. Flange: Both sides with pressurestrengthened solid rubber flanges, drilled according to specific requirements with onepiece steel backing flanges of material S 2 JRG 2 (RSt 32) with corrosion protection. Design I Design II Design III Design IV with loose backing flanges with vulcanized backing flanges with loose backing flanges and supporting collar with vulcanized backing flanges and in the bellows vulcanized steel rings Design I Design II Note: For aggressive media, contact James Walker Townson. The bellows must not be painted or insulated. See installation information in Annex. Design III Design IV 1 To order or get further details, call your local contact shown on rear cover or listed at

15 Standard overall length Variable overall length t rubber and steel ax + Movement absorption for the standard ax lat ± ± Standard pressure bar Max. pressure bar *Note: Our bellows, type 2, are manufactured in four different flange designs. The pressure indicated in the chart is the max. possible manufacturing technical operating pressure. However, the bellows are manufactured specifically to the operating pressure stated in the order. To order or get further details, call your local contact shown on rear cover or listed at

16 James Walker Townson Rubber Comflex Expansion Joint 5 5 is a low corrugated rubber Comflex Expansion Joint with good noise absorbing characteristics and high expansion absorption in all three planes. Because of its low corrugation, with outstanding noise and vibration absorbing qualities as well as high expansion absorption in all directions a very low adjusting force is possible. TYPE 5 Design Low twocorrugated rubber bellows with nylonreinforcing inserts and integral sealing bead (therefore selfsealing without additional gasket) for accoodating threepiece unions (DIN EN conical). Available with or without solidring between the corrugations externally. Connections 5 red both sides: With malleable cast iron, galvanized unions 5 blue both sides: With red brassbrass or highgrade steel unions 5 blue with drinking water approval acc. to KTW Details for type 5 Bellows colour code Core inner Reinforcing material Cover outer Permissible operating data bar C bar C bar C Vacuum Hardness shore A red blue Tw Nylon Nylon bar abs. 0.5 bar abs. 0 0 Bellows Connection Movement absorption Overall length ØA GL SW SW R inch ax + ax lat ± ± Weight kg For installation information, see page 59 1 To order or get further details, call your local contact shown on rear cover or listed at

17 James Walker Townson Rubber Comflex Expansion Joint TYPE, in a low corrugated high pressure design, is suitable for sanitary, heating, airconditioning and swiing pool use, as well as for solar technology. Also for apparatus, pipeline and motor construction. It absorbs thermal expansions and vibration, compensates for axial and lateral movements, and is resistant to chemical and mechanical stresses. Approvals: redst. and redsp with TÜV approval for heating systems in accordance with DIN 09. PED 923EG Details for type Bellows colour code redsp Core (inner) Bellows design Reinforcing material Aramide Cover (outer) Permissible operating data Electrical resistance bar C bar C bar C Ohm cm x 2 Hardness shore A 0 redst Steel cord x 2 0 blue IIR 5 x 2 55 yellow NBR x 3 5 grey 1 5 x 0 red 1 90 x 2 5 white NBR x 3 0 green CSM CSM x 3 5 Burst pressure > bar, suitable for 0.5 bar abs. Construction: Low corrugated rubber expansion joint with reinforcing inserts and builtin sealing profile with rear mounted female thread for mating to threaded connecting pieces, with male or female threaded joints. The expansion joint bellows bead is selfsealing. Bracing: Under pressure the Comflex Expansion Joint bellows develops a reaction force in the axial direction. This force has to be reduced by adequate anchor points or restraints fastened on the piping. No additional gaskets are required. (Seal threaded joints in piping as usual) Connecting pieces: white: Malleable cast iron, galvanized union nut with MS or RG thread. Other types : Union nut and screwin parts from galvanized malleable cast iron. Special connections in stainless steel are possible. Important note: Ensure torsionfree installation. The bellows must not be insulated or painted. For installation information, see page 52. To order or get further details, call your local contact 1 shown on rear cover or listed at 1

18 Application: For heating systems, in acc. with DIN 09 red aramide With corrosionprotected aramide inserts. redsteelcord For long service life in heating and hot water at 0 C1 C and bar bar pressure for year service life. Not suitable for oilrelated media. green TYPE For chemical plants For heavy chemical use up to 1 bar working pressure. Permissible temperature, working pressure and life expectancy depend in individual cases on medium and concentration. Resistance table on request. blue nylon For drinking water hot water For cold and hot water (up to 5 C), also with the addition of chemicals for water treatment. Industrial water, acids, lyes, alcohols, esters and ketones. Not suitable for oilrelated media. For oil, fuel, gas yellow Electroconductive, R = 3 up to Ohm. yellow Application: town and natural gas. steel cord Blastfurnace, fuels, lubricants, heating oil, cooling water emulsions. white red For food processing and beverage industry Also suitable for oilrelated and fatty foodstuff. Suitable up to +0 C. For warm water For cold and hot water (up to 90 C), also with the addition of chemicals for water treatment. Industrial water, acids, lyes, alcohols, esters and ketones. Not suitable for oilrelated media. grey For water pipes For cold and hot water, washing water, sea water, swiing pool water, waste water (also oilrelated, weak acid or alkaline with ). Overall Bellows Width across Expansion absorption Expansion absorption length Overall Effec. Flats up to C over C length ØA surface R GL 1 GL axial lat. 2 SW 1 SW 2 SW 3 axial lat cm 2 thread Weight Des. 2 1 kg Des. kg To order or get further details, call your local contact shown on rear cover or listed at

19 James Walker Townson Rubber Comflex Expansion Joint is a high corrugation rubber Comflex Expansion Joint with very good noise absorbing characteristics and high expansion absorption in all three planes. TYPE Design High corrugated rubber bellows with reinforcing inserts and integral sealing bead (therefore selfsealing without additional gasket) to suit the steelbacked swivel flanges with solid ring support. The flanges are provided with throughholes (PN, PN, PN1, ASA0 lbs, etc.). All steel parts in S2 JRG2 (RSt 32) are zincplated and yellow passivated. Other specifications in acc. with DIN, ASA, BS Special flanges are available. (PN, PN, PN1, ASA 0 lbs or others). All steel parts in S 2 JRG2 (RSt 32) are zinc plated and yellow passivated. Details for type Bellows colour code Core inner Reinforcing material Cover outer Permissible operating pressure bar C bar C bar C Electrical resistance [Ohm cm] Hardness shore A red grey Special Cord * 5* 55 0 red grey for hot water plants and lyes for waste water and cooling water plants Bellows Flange PN Movement absorption Overall length ØA ØD ØPC Ød n s ax ax lat ± ± ØC Special designs With tierods design B as axial stroke limitation and for absorption of the reaction forces. With tierods design C as axial stroke and thrust limitation, tierods in rubber bushes. To order or get further details, call your local contact 19 shown on rear cover or listed at 19

20 James Walker Townson Rubber Comflex Expansion Joint 9 Manufactured by Continental TYPE 9 9 is a heavy duty rubber Comflex Expansion Joint of a highly flexible design. Its high corrugation allows an extremely short overall length with excellent noise and vibration absorbing characteristics as well as high expansion absorption in all directions at very low movement forces. Design: High corrugated bellows body with integral sealing profile (therefore selfsealing without additional gasket) for mating with swivel flanges. The flanges are provided with threaded holes as the bellows is supported on the flange. Details for type 9 Bellows colour code Core (inner) Design of the bellows Reinforcing material Cover (outer) Permissible operating data Electrical resistance bar* C bar* C bar C [Ohm m] Hardness shore A red Nomex x blue IIR 1 90 x yellow NBR 1 90 x 3 white NBR white x 3 green CSM CSM 1 90 x **)black IIR 5 x Suitable for vacuum up to 0. bar abs. without supporting ring (2 m suction) Suitable for vacuum up to 0 bar abs. with supporting ring ( m suction) All expansion joints can be delivered with earthing straps *) to 0 from 0 **) 0, burst pressure > 0 bar A Flange: (Design A) Swivel flanges on both sides with integral rubber profile, so that an additional gasket is not required (selfsealing). The flange holes are DIN PN standard, with threaded boltholes. Other flange specifications in accordance with DIN, ASA, BS. Special flanges are also available. The flange is produced with appropriate threaded holes; throughbolts cannot be used. Approvals: 9 Ared with TÜVDIN 09 for heating installation, Technical Control Number 3 E001 9 white Suitable for foodstuff RALC 53 9 blue with Drinking Water Approval RALC 52 and 19 Federal Health Bureau KTW Rubber Coitee Flange material: Other materials available on request. Standard S 2 JRG2 (RSt32) zinc plated and yellow passivated. 9 all Ship Licence with or without flame protective cover, depending on installation location. PED 923EG To order or get further details, call your local contact shown on rear cover or listed at

21 Application: 9 For heating systems, as per DIN 09 Ared For continuous duty in warm and hot water heating at 0 C1 C and barbar working pressure over life. Not suitable for oilrelated media. TYPE 9 9 blue 9 white 9 green 9 yellow 9 black For drinking water hot water For cold and hot water, also with the addition of chemicals for water treatment. Industrial water, acids, lyes, alcohols, esters and ketones. Not suitable for oilrelated media. For the food and beverage industry Also suitable for oil and fatcontaining foodstuff. For chemical plants For heavy chemical use. For oil, fuel, gas Application range: natural and town gas, blast furnace gas, fuels, lubricants, heating, cooling water emulsions. For water pipes For cold and hot water, water with detergents, sea water, swiing pool water, waste water. Not suitable for oilrelated media Overall length cm Permissible % of indicated movement relative to temperature: up to C ~ 0% up to C ~ 0% up to 90 C ~ % Note: For aggressive media please contact James Walker Townson. The bellows must not be painted or insulated. See further installation information in Annex. D Flange PN Movement absorption Weight Bellows ØA Eff. surface ØPC Ød n s axial lat. * ØC kg M1 M1 M1 M1 M1 M1 M1 M M M M M M M2 M * Only valid for an assembly shortened by about (900). Accessories: Tie barrestraints See page Deflector sleeve See page Flameproof protective covers See page Earth Covers See page 51 To order or get further details, call your local contact 21 shown on rear cover or listed at 21

22 Tie bar (Standard Designs B + C) TYPE 9 Since the rubber bellows is a soft flexible component, it must be observed that under pressure the expansion joint will always try to move in the axial direction because of its reaction force (cross section area x working pressure). It must be ensured by constructive measures on the piping (roller bearing, restraining or anchor points) or tie bars directly on the expansion joint that any overextension of the bellows is avoided. See our range of tie bars on pages + 9. Design B Design C Flange shapes for tie bars as per designs B and C at bar Overall length Main dimension for PN s A ØB To order or get further details, call your local contact shown on rear cover or listed at

23 TYPE 9 Vacuum Supporting Rings James Walker Townson type 9 Comflex Expansion Joints are suitable for vacuum. To prevent the expansion joint bellows being drawn together by suction at negative pressure, the insertion of a vacuum supporting ring is necessary for a pressure above 2m (0.bar abs., % negative pressure). Bolt Packs SU Hexagon bolts according to DIN EN 21 Washers DIN EN ISO 9 and 90 Selected bolt packs are available for connecting type 9 expansion joints to piping, so that by using DIN flanges, the bolt lengths are flush with the expansion joint bellows ArtNo For installation, ensure smooth, burrfree surfaces on the rubber bellows using the Uwashers for length correction (place under bolt head). Contents Bolt pack Quantity Bolts Quantity UWashers kg DIN 933. Ø Accessory bolt packs PN SU 1 SU 1 SU 1 SU 1 SU SU SU 5 SU SU SU SU 9 SU 11 SU SU SU 1 DINNorms PN PN1 SU 2 SU 2 SU 3 SU 3 SU SU SU SU SU SU SU 13 SU 1 SU SU 19 SU SU 2 SU 2 SU 3 SU 3 SU SU SU SU SU SU 11 SU 1 SU 1 SU 19 SU 21 SU SU 1 SU 2 SU 3 SU SU 5 SU SU SU SU 9 SU SU 11 SU SU 13 SU 1 SU SU 1 SU 1 SU 1 SU 19 SU SU 21 SU M X M 1X M 1X M 1X M 1X M 1X M 1X M 1X5 M 1X5 M X5 M X5 M X5 M X M X M X M X M 2X M 2X M 2X55 M 2X55 M 2X0 M X To order or get further details, call your local contact 23 shown on rear cover or listed at 23

24 James Walker Townson Rubber Comflex Expansion Joint Manufactured by Continental is a low corrugated bellows Comflex Expansion Joint with good sound insulating characteristics for structure and liquidborne noise. It is characterized by a very high expansion capability, particularly in the angular plane. TYPE Design: Low corrugated rubber bellows with reinforcing inserts and integral sealing bead (therefore selfsealing without additional gaskets) for accoodating the swivel flanges. The flanges are provided with through holes. Details for type Bellows colour code red aramide Core (inner) Bellows design Reinforcing material Aramide Cover (outer) Permissible operating data bar C *) 1 bar C **) 0 Electrical resistance bar C ***) [Ohm m] 1 1 x Hardness shore A 0 red IIR x 55 white NBR x 5 green CSM CSM 1 90 x 5 yellow NBR 1 90 x 3 0 orange NBR Nylon S 1 x 3 0 yellowsteel cord NBR Steel cord x 11 0 black 1 1 x 11 0 black IIR 5 x 55 Suitable for vacuum up to 0.bar abs., without supporting ring (2 m suction) Suitable for vacuum up to 0bar abs., with supporting ring ( m suction) All Comflex Expansion Joints can be delivered with earthing straps. A Flanges: (Design A) Swivel flanges both sides (Design A) with integral rubber profile, so that additional gaskets are not required (selfsealing). The flanges are drilled acc. to DIN PN as standard. Other specifications in accordance with DIN, ASA, BS. Special flanges are also available. Flange material: Standard S 2 JRG2 (RSt 32) zinc plated and yellow passivated. *) 0 00 = bar **) 0 00 = bar ***) 0 00 = bar Burst pressure 00 > bar Burst pressure 0 00 > bar Approvals: with TÜVDIN approval, DIN 09 redaramid for heating installation, Technical Control Number 3 E 003 red with Drinking Water Approval in accordance with 19 Federal health Bureau KTW Rubber Coittee white Suitable for foodstuff. all Marine Approval with or without flame protective cover. Other materials available on request. (Flanges up to 0 are in some cases made with forged collars for the bellows side). 2 To order or get further details, call your local contact shown on rear cover or listed at

25 Application: For heating systems, as per DIN 09. red With corrosionproofed aramide inserts. aramide For continuous duty in hot water heating and high temperature water central heating at 0 C 1 C and bar bar working pressure over a year working life. Not suitable for oilrelated media. For drinking water hot water red nylon For cold and hot water (up to 90 C), also with the addition of chemicals for water treatment. Industrial water, acids, lyes, alcohols, esters and ketones. Not suitable for oilrelated media. white green For the food and beverage industry Also suitable for oil and fatcontaining foodstuff. May be used up to +90 C. For chemical plants For heavy chemical use up to 1 bar working pressure. Permissible temperature, working pressure and life expectancy depend in individual cases on medium and concentration. Resistance table on request. yellow yellowsteel cord black black TYPE For oil, fuel, gas Electroconductive, R = 3 to Ohm. Application range: natural and town gas, blast furnace gas, fuels, lubricants, heating oil, cooling water emulsions. For water pipes For cold and hot water, water with detergents, sea water, swiing bath water, waste water with (also oilrelated, weak acid or alkaline) (In only available up to 0) orange Overall length For oil, fuel, gas Electroconductive, R = x 3 Ohm. Application range: Natural and town gas, blast furnace gas, liquid gas acc. to DIN 52, fuels, lubricants, heating oil, cooling water emulsion. For standard types Bellows Flange PN Movement absorption cm ØA Effective surface ØD ØPC Ød n Permissible % of indicated movement relative to temperature: up to C ~ 0%, up to C ~ 5%, up to 90 C ~ 0% s With steel cord Movement absorption ØC axial lat. axial lat To order or get further details, call your local contact shown on rear cover or listed at

26 Stiffness rate axial for type (average value by full way) Overall length 0 bar N 2,5 bar N bar N bar N bar N Stiffness rate lateral for type (average value by full way) Overall length 0 bar N 2,5 bar N bar N bar N bar N Attention: Variations in stiffness rate is possible by material reinforcing or production process change with +%. 2 To order or get further details, call your local contact shown on rear cover or listed at

27 Tie bar (Standard designs B and C) TYPE Since the rubber bellows is a soft flexible component, under pressure the expansion joint will always try to move in the axial direction because of its reaction force (bellows cross section area x working pressure). It must be ensured by constructive measures on the piping (roller bearing, restraining or anchor points) or tie bars directly on the expansion joint that any overextension of the bellows is avoided. See tie bar range on pages and 9. Design B Design C Vacuum supporting ring in 1.51 Flange shapes for tie bars as per designs B and C ArtNo (00) 00 Vacuum supporting ring James Walker Townson type expansion joints are vacuumresistant. To prevent the expansion joint bellows being drawn together by suction at negative pressure, the insertion of a vacuum supporting ring is necessary for a suction value above 2 m (0. bar abs., % negative pressure) ArtNo Application example for a gimbal flange design for joint pipe angulation 0 Note: For aggressive media, see resistance table. The bellows must not be painted or insulated. Further installation information is provided in the Annex. Accessories: Tie barrestraints See page Deflector sleeve See page Flameproof protection cover See page Earth cover See page 51 To order or get further details, call your local contact 2 shown on rear cover or listed at 2

28 PTFE chemical design TYPE in a special design has a PTFE foil liner for effective resistance against aggressive chemicals. The PTFE liner is suitable for all coonly used liquids; attention should be paid to heat resistance. The expansion joint should only be used in higher pressure ranges (up to max. bar); not safe for vacuums. A special PTFE supporting ring is available for vacuums, but only for Bellows Overall length ØA Eff. surface ØD cm Flange PN Movement absorption ØPC n axial lateral Ød s ØC To order or get further details, call your local contact shown on rear cover or listed at

29 James Walker Townson Rubber Comflex Expansion Joint 51 lilac 51 lilac is a special type similar to the series and is manufactured by a special process. TYPE 51 Suitable for chemical plants, particularly for higher thermal duty up to about C. The highest permissible duty depends on temperature, pressure, movement and life expectancy. Note: The bellows must not be painted or insulated. Bellows colour code Core (inner) Bellows design Reinf. material Cover (outer) Permissible working data bar C bar C bar C lilacred lilac FKM FKM Aramide Aramide Burst pressure > bar Suitable for vacuum up to.0 bar abs., without supporting ring (2 m suction). Suitable for vacuum up to 0 bar abs., with supporting ring ( m suction) Overall Bellows length Eff. surface cm Flange PN Movement absorption ØA ØD ØPC Ød n s axial lat. + + ØC To order or get further details, call your local contact 29 shown on rear cover or listed at 29

30 James Walker Townson Rubber Comflex Expansion Joint 53 TYPE is a low corrugated bellows Comflex Expansion Joint with good sound insulating characteristics. It is characterized by a very high expansion capability in all three planes. Design: Low corrugated rubber bellows with reinforcing inserts and integral sealing bead (therefore selfsealing without additional gaskets) for accoodating the steelbacked swivel flange with solid ring support. The flanges are provided with through holes (PN, PN, PN 1, ASA0 lbs, etc.). All steel parts in S 2 JRG2 (RSt 32) are zinc plated and passivated. Details for type 53 Bellows colour code Core (inner) Reinforcing material Cover (outer) Permissible operating data bar C bar C bar C Hardness shore A redblue yellow blue greenblue IIRD NBR CSM Aramid Aramid Aramid CSM Suitable for vacuum up to.0 bar abs., without supporting ring. Suitable for vacuum up to 0 bar abs., with supporting ring. Design A Bellows Flange PN Movement absorption Overall length ØA ØD ØPC Ød n s 1 1 ax + ax lat ± ± C Special designs With tierods design B as axial stroke limitation and for absorption of the reaction forces. With tierods design C as axial stroke and thrust limitation, tierods supported in rubber bushes. Design C Design B To order or get further details, call your local contact shown on rear cover or listed at

31 James Walker Townson Rubber Comflex Expansion Joint 5 yellow TYPE 5 5 yellow is a low corrugated bellows Comflex Expansion Joint with good sound insulating characteristics. It is characterized by a very high expansion capability in all three planes. Design: Low corrugated rubber bellows with reinforcing inserts and integral sealing bead (therefore selfsealing without additional gasket) for accoodating steelbacked swivel flanges with solid ring support. The flanges SAE 00 are provided with through holes. All steel parts in S2JRG2 (R St 32) are zincplated and passivated. Note: The flanges are also available in other standards, e.g. DIN PN,, 1 or ASA0 lb. Details for type 5 yellow Bellows colour code Core (inner) Reinforcing material Cover (outer) Permissible operating data Electrical resistance Hardness shore A bar C bar C bar C [Ohm cm] yellow NBR Nylon 0 5* 0 Suitable for vacuum up to.0 bar abs., without supporting ring. Suitable for vacuum up to 0 bar abs., with supporting ring Overall length n Bellows Flange SAE 0 Movement absorption Ødi A B D E Ød n s ax + ax lat ± ± ØC To order or get further details, call your local contact 31 shown on rear cover or listed at 31

32 James Walker Townson Rubber Comflex Expansion Joint 55 TYPE is a low corrugated bellows Comflex Expansion Joint with good sound insulating characteristics (structure and liquidborne noise). It is characterized by a high expansion absorption capability, in particular angular expansion. Design: Low corrugated rubber bellows with reinforcing inserts and integral sealing beads (therefore selfsealing without additional gaskets) for accoodating swivel flanges. The flanges are provided with through holes. Other bellows designs similar to type are available on request. Details for type 55 Bellows colour code redsp Core (inner) Bellows design Reinforcing material Aramid Cover (outer) Permissible operating data Electrical resistance bar*) C bar**) C bar***) C [Ohm m] x 3 Hardness shore A 0 red IIR 1 90 x 55 yellow NBR 1 90 x 3 0 green CSM CSM 1 90 x 5 Burst pressure > bar Suitable for vacuum up to.0 bar abs., without supporting ring. Suitable for vacuum up to 0 bar abs., with supporting ring. *) 00 = bar **) 00 = bar ***) 00 = bar Burst pressure 00 > bar Burst pressure 0 > bar Other bellows constructions as type available on request. Flange: (Design A) Swivel flanges both sides (design A) with integral rubber profile, so that additional gaskets are not required (selfsealing). The flanges are drilled to DIN PN as standard. Other specifications in accordance with DIN, ASA, BS. Special flanges are also available. Flange material: Standard S 2 JRG2 (RSt 32) zincplated and yellow passivated. Other materials are available on request (flanges up to 0 are partly provided with forged collars towards the bellows side.) Design A Note: For aggressive media, contact James Walker Townson. The bellows must not be painted or insulated. Further installation information, see Annex. Vacuum supporting rings James Walker Townson expansion joints type are vacuumresistant. To prevent the expansion joint bellows being drawn together by suction at negative pressure, the insertion of a vacuum supporting spiral (up to 0) alternatively a vacuum supporting ring (from ) is necessary for a suction value above 2 m (0. bar abs., % negative pressure). To order or get further details, call your local contact shown on rear cover or listed at

33 Application: 55 red 55 yellow For heating water For cold and hot water, also with the addition of chemicals for water treatment. Industrial water, acids, lyes, alcohols, esters and ketones. Not suitable for oilrelated media. For oil, fuel, gas Application range: natural and town gas, blast furnace gas, fuels, lubricants, heating oil, cooling water emulsions. TYPE For heating systems, as per DIN 09 redsp With corrosionproofed aramide inserts. For continuous duty in hot water heating and high temperature water central heating at 0 C 1 C and bar bar working pressure over a year working life. Not suitable for oilrelated media. 55 all All types with GLImproved Overall length Bellows ØA Eff. ØD surface cm Permissible % of indicated movement relative to temperature: up to C ~ 0% up to C ~ 5% up to 90 C ~ 0% Flange PN Movement absorption ØPC Ød n s ØC ax + ax lat Accessories: Tie barrestraints See page Deflector sleeve See page Flameproof protection covers See page Earth cover See page 51 To order or get further details, call your local contact 33 shown on rear cover or listed at 33

34 James Walker Townson Rubber Comflex Expansion Joint 5 5 is a handbuilt cylindrical Comflex Expansion Joint. This process allows the overall length to be varied. It is only designed to compensate for lateral and angular movements. By its corrugatedfree design an easy flow is possible with no sediment deposit. TYPE 5 Design: Cylindrical bellows body with reinforcing inserts and builtin rubber profile for mating with swivel flanges. The expansion joint is selfsealing, additional gaskets are not required. Application: Noise and vibration damper, thermal expansion absorption in delivery pipe lines, on containers and pumps for media containing solid material. Details for type 5 Bellows colour code Core (inner) Reinforcing material Cover (outer) Permissible operating data Electrical resistance Hardness shore A bar C bar C [Ohm cm] red yellow green white lilac NBR CSM NBRwhite FPM Aramid CSM x 3 5 x 3 x 5 x Burst pressure > bar Flange: Swivel flanges (design A) both sides with integral sealing bead, no additional gaskets required (selfsealing). Flanges are drilled acc. to DIN PN as standard. Other specifications according to DIN, ASA, BS and special flanges are also available. Flange Material: Standard S 2 JRG2 (RSt 32) zinc plated and yellow passivated. Other materials available on request. Note: Applicable only for lateral and angular movement (crease formation). Do not paint or insulate. See installation information Overall length C ØD ØPC Flange PN Ød n s Perm. pressure bar lat ± Weight length 0 kg To order or get further details, call your local contact shown on rear cover or listed at

35 James Walker Townson Rubber Comflex Expansion Joint 5 TYPE 5 5 is a conical Comflex Expansion Joint produced by hand winding. Its overall length cannot be varied. We have an extensive mould form package which is available on request. Due to its configuration, type 5 expansion compensation is only possible in the lateral and angular plane. Design: Conical bellows body with reinforcing inserts and integral rubber profiles for mating with swivel flanges. The expansion joint is selfsealing, additional gaskets are not required. Application: Noise and vibration damper for use in delivery pipe lines, containers, building outlets and pumps, and wherever a connection bridging piece allowing smooth free flow is required owing to the composition of the medium. Details for type 5 Bellows colour code Core (inner) Reinforcing material Cover (outer) Permissible operating data Electrical resistance Hardness shore A bar C bar C [Ohm cm] red yellow green white lilac NBR CSM NBRwhite FKM Kevlar CSM x 3 5 x 3 x 5 x Burst pressure > 2 bar Flanges: Swivel flanges both sides (Design A) with integral rubber profile, no additional gaskets required (selfsealing). The flanges are drilled according to DIN PN as standard. Other specifications according to DIN, ASA, BS and special flanges are also available. Flange Material: Standard S 2 JRG2 (RSt 32), zinc plated and yellow passivated. Other materials available on request. Tie barrestraints: It is recoended that these expansion joint elements be installed with internal bracing. Due to the build up of pressure, elastic deformation occurs which can distend the conical bellows body. This causes the expansion joint to either compress or high tensile loads to be exerted on the connecting parts. To order or get further details, call your local contact shown on rear cover or listed at

36 TYPE Overall length ØC ØD Flange 1 ØPC n x Ød x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x x x x x x x x ØC ØD Flange 2 n x Ød ØPC x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x 1 x x x x x s Perm. pressure bar lat ± Special Designs: Eccentric construction, larger nominal diameters and other sizes available on request. Note: For aggressive media, refer to resistance table. The bellows must not be painted or insulated. For further installation information, see page To order or get further details, call your local contact shown on rear cover or listed at

37 James Walker Townson Rubber Comflex Expansion Joint 5 5 is a cylindrical Comflex Expansion Joint produced by hand winding. The manufacturing process allows production in variable overall lengths. It is only able to compensate for movement in lateral and angular planes due to its design. TYPE 5 Design: Cylindrical rubber bellows body with reinforcing inserts and integral reinforced solid rubber flanges as well as separate backing support flanges. Application: Noise and vibration damper as well as expansion expansion joint for use in delivery pipe lines, containers, building outlets and pumps, and wherever a connection bridging piece allowing a smooth free flow is required. Details for type 5 Bellows colour code Core (inner) Reinforcing material Cover (outer) Permissible operating data Electrical resistance Hardness shore A bar C bar C [Ohm cm] red yellowst yellow green white lilac NBR NBR CSM NBRwhite FKM Steel cord Aramid CSM x 3 1 x 2 5 x 3 x 5 x Burst pressure > 2 bar Flange: Pressure resistant solid rubber flanges with reinforcing inserts and 2piece backing flanges in S 2 JRG2 (RSt 32) drilled according to DIN PN. Other materials and hole sizes available on request. The Comflex Expansion Joint is selfsealing and no additional gaskets are required. Note: Only suitable for lateral and angular movements. Mating flanges must be flat without projections or recesses. Do not insulate or paint. See installation information Overall length ØD ØPC Flange PN Ød n bar b s Perm. press. lat. + To order or get further details, call your local contact 3 shown on rear cover or listed at 3

38 James Walker Townson Rubber Comflex Expansion Joint 59 TYPE is a conical rubber bellows produced by hand winding for absorbing lateral and angular movements. Its overall length can only be varied by the production of new moulds. However, an extended range of moulds is available. Only the standard range is shown in this brochure. Please consult us when planning. Design: Conical rubber bellows body with reinforcing inserts and integral reinforcing solid rubber flanges and backing support flanges. Application: Noise, vibration and underwater sound damper for use in delivery pipe lines, containers, pumps and building outlets, and wherever a connection bridging piece allowing a smooth free flow is required. Details for type 59 Bellows colour code Core (inner) Reinforcing material Cover (outer) Permissible operating data Electrical resistance Hardness shore A bar C bar C [Ohm cm] red yellowst yellow green white lilac NBR NBR CSM NBRwhite FPM Steel cord Aramid CSM x 3 1 x 2 5 x 3 x 5 x Flanges: Pressure resistant solid rubber flanges with reinforcing inserts and 1piece backing flanges in S 2 JRG2 (RSt 32) drilled acc. to DIN PN. Other materials and hole sizes are available on request. The expansion joint is selfsealing, no additional gaskets are required. Special designs: Eccentric construction, larger nominal diameters and other sizes available on request. Tie barrestraints: It is recoended that these expansion joint elements be installed with internal bracing. Due to the build up of pressure, elastic deformation occurs which can distend the conical bellows body. This causes the expansion joint either to compress or high tensile loads to be exerted on the connecting parts. Special designs with reinforced bellows parts available (no distension). Note: Only suitable for lateral and angular movement. Mating flanges must be smooth without projections or recesses. Do not insulate or paint. See installation information Overall length s b ØD Flange 1 ØPC n x Ød x 1 x 1 x 1 x 1 x x x x x x x x 1 x 1 x 1 x 2 1 x 2 x 2 x 2 x 2 x 2 ØD Flange 2 ØPC n x Ød x 1 x 1 x 1 x 1 x 1 x 1 x 1 x x x x x x x 1 1 x 1 x 2 1 x 2 x 2 Perm. press. bar lat. + 3 To order or get further details, call your local contact shown on rear cover or listed at

39 James Walker Townson Pipe Joint 0 WRG 0 is a rubber metal pipe joint for inhibiting noise and surface vibrations in piping on pumps, machines and apparatus. TYPE 0 TÜV approved for installation in heating systems with 01 C and bar. Design: Cylindrical rubber buffer with vulcanized flange rings for accoodating the flange holes. The rubber metal pipe joint is selfsealing and no additional gaskets are required. Application: Building installations, hospitals and schools, in heating systems and in water, hot water systems; also suitable for use weak acids and lyes in industrial plants. Material: Rubber parts without inserts. Steel flange rings with threaded holes. Only manufactured in. Design PN Design PN Overall length Bellows effec. surface Flange PN ØD ØPC Ød n Weight Overall length Bellows effec. surface Flange PN ØD ØPC Ød n Weight cm 2 kg cm 2 kg M M M M M M M M M M M M M M M M M M M M 5.5 0* M M.5 *without TÜV Installation information: Reliable functioning requires perfect pipeline layout and precisely designed pipe anchors. The rubber metal pipe connections should be installed stressfree. Installation gaps should be. Tension, torsion or bending loads must be avoided. Installation should be in an easily accessible location so that maintenance and checks can be carried out. If stressfree installation is not possible or if axial or radial movement is expected, then James Walker Townson rubber expansion joints should be used. Additional gaskets are not required since the mating surface is of rubber. Assembly takes place with hexagon head cap screws DIN EN 21 and plain washers. Tightening torque is 3kpm. Do not insulate James Walker Townson pipe joints (heat accumulation!). To order or get further details, call your local contact 39 shown on rear cover or listed at 39

40 James Walker Townson Rubber Comflex Expansion Joint 1 TYPE 1 1 is a low corrugated rubber Comflex Expansion Joint, characterized by its cylindrical end connections, which make quick and easy clamp fitting possible. Design: Low corrugated rubber body with reinforcement inserts, cylindrical at both ends for clamp fixing. Application: Wastewater piping, motor cooling systems, industrial plants, ventilation plants, purification plants. Details for type 1 Bellows colour code Core (inner) Reinforcing material Cover (outer) Permissible operating data Electrical resistance Hardness shore A bar C bar C [Ohm cm] redst red yellowst yellow green white lilac NBR NBR CSM NBRwhite FKM Steel cord Steel cord Aramid CSM x 3 x 2 5 x 5 x 3 x 5 x Burst pressure >2 bar, vacuum resistant with supporting ring Note: Special measurements are possible. Pipeline outside diameter must be clean and smooth (grind down any weld seams). Do not insulate or paint the bellows. Use wide clamps (min. x1). Up to 2 bar, one clamp per side can be used. Above 2 bar, we recoend the use of 2 clamps per side. Ødi Overall length ØA s H B ax + Movement absorption ax lat ± ± Weight kg Bigger nominal width possible To order or get further details, call your local contact shown on rear cover or listed at

41 James Walker Townson Draining Hose 2 2 has been especially developed for bridge drainage and is able to meet all the demands of this heavy duty application, e.g. large temperature fluctuations, different media, vibration and large extension absorption. To be mentioned in particular is its flexible design with a very low adjustment force. TYPE 2 Design: Core and covering corrugated throughout with concealed integrated steel wire spiral and corresponding fabric inserts. Spiralfree sleeves at each end for clamp fixing. Material: Chloroprene with nylon fabric inserts. Stainless steel or galvanized clamps. When used in conjunction with SMLpipes the following hose diameters are available: Note: Check existing temperature during installation and install appropriately pretensioned. Do not insulate or paint the hose. When ordering quote the pipe diameter of the sleeve extension. The hose is only suitable for unpressurized operation. ØDE Ø Li H Spiral free sleeves at each end, can be extended as required. Axial compression takeup abt. %, lateral extension takeup abt. + % of flexible length. s Length To order or get further details, call your local contact 1 shown on rear cover or listed at 1

42 James Walker Townson Rubber Comflex Expansion Joint 3 3 is a rubber Comflex Expansion Joint that can be manufactured to specific design dimensions. There are no standard sizes for this particular type. The overall length is variable and depends on the amount of movement to be compensated. TYPE 3 Application: For air, water and chemical installations as well as internal or external throughwall installation in power stations. Details for type 3 Bellows colour code Core (inner) Bellows design Reinforcing material Cover (outer) Permissible operating data max bar max C Hardness shore A red yellow black green white lilac IIR NBR CSM SIL FKM Polyester Fabric Polyester Fabric Polyester Fabric Polyester Fabric Glass Fabric Stainless Steel IIR NBR CSM SIL FKM Note: The permissible pressure stability is largely shape dependent. Available in all shapes: round, rectangular or oval. Operating pressure must be determined depending on shape (round max. bar, rectangular max. 2 bar). Do not paint or insulate! See installation information! wall sealing with clamps wall sealing with flange 2 To order or get further details, call your local contact shown on rear cover or listed at

43 James Walker Townson Rubber Comflex Expansion Joint TYPE is a Comflex Expansion Joint that can be manufactured to specific design dimensions. There are no standard dimensions for this particular type. The overall length is variable and depends on the amount of movement to be compensated. The expansion joint is manufactured from prefabricated foils and depending on the material is vulcanized or heated in the final form. Applications: The diverse materials used make type suitable for a wide range of applications, e.g. problems when handling hot gases and the associated condensate in scrubbing and flue gas systems. Compared to metal expansion joints, type in the shortest overall length is capable of absorbing significant axial and lateral expansion and compensate assembly inaccuracies. Noise and vibrations from equipment, e.g. fans, etc., are simultaneously absorbed. Movement: axial = ~ 0,3 x L axial = ~ 0,05 x L lateral ± = ~ 0,1 x L We can improve the movement by corrugation design and choice of material. To order or get further details, call your local contact 3 shown on rear cover or listed at 3

44 Standard designs: is manufactured in two basic designs: Firstly, as a hosetype and a flangetype expansion joint. Both can be manufactured with flat convex or concave profiles for round and rectangular piping systems in all sizes. The material thickness varies depending on the design between 1 and. The connection surfaces in way of the bellows are appropriately reinforced, so that troublefree connection with clip or flange bolt connection is possible. It should also be noted, that the expansion joints with flange design are available preshaped up to a diameter of ; for larger dimensions, these components are supplied flat so that the flanges can be erected during assembly. Applications: Plant construction, power stations, combustion gas desulphurization plants, purification plant, rain water systems, pipe wall penetrations, etc. Note: See installation information. The expansion joints should not be painted or insulated as this can cause premature failure of the materials! In case of enquiries, please specify the particular design and respective hole pattern. data Bellows colour code Core (inner) Bellows design Reinforcing material Cover (outer) Permissible operating data max. bar max. C Hardness shore A red grey none none FKM PTFE FKM To order or get further details, call your local contact shown on rear cover or listed at

45 James Walker Townson PTFE Comflex Expansion Joint 0 0 is a PTFE expansion bellows Comflex Expansion Joint hotformed from extruded PTFE tubing under pressure to form continuous corrugations. TYPE 0 Design: Pure PTFE bellows with external stainless steel supporting rings, PTFE profiles on both sides with steel backingflange and integral brace. Application: Chemical plants, for movement and noise reduction as well as compensation of assembly inaccuracies. Recoended for use in piping of fragile materials, e.g. glass, graphite, enamel. Minimal compensating forces are necessary due to the elasticity of the material. Power curve under pressure Power curve in vacuum curve over pressure under vacuum Important installation information: It is imperative that gaskets are used except in the case of PTFEPTFEconnections, e.g. PTFE covered IT gaskets (Design 1) or PTFE covered IT gaskets with stainless steel inserts (Design 2) or their equivalent. Flanges: Steel edge flanges with antirust coating on both sides, drilled acc. to DIN PN. Other materials and hole patterns available. Note: Not suitable for vibrations! Do not insulate! See installation information! Special designs: For glass tubing. For total vacuum. For higher working pressure. Available on request. 1 2 Special construction up to PN 1 possible in 2 corrugated design ( 0 HD). To order or get further details, call your local contact 5 shown on rear cover or listed at 5

46 To order or get further details, call your local contact shown on rear cover or listed at TYPE ax ± N lat ± N Convolutions ax ± N lat ± N 5 Convolutions Movement forces type Effec. bellows surface cm 2 cm 2 Movement absorption + axial Flange ØD Ød n s ØC Overall length + axial Movement absorption + lat. lat. 3 Convolutions 5 Convolutions Weight Weight ØPC length kg kg

47 James Walker Townson PTFE Comflex Expansion Joint 0 HD TYPE 0 HD 0 is a PTFE expansion bellows Comflex Expansion Joint hotformed from extruded PTFE tubing under pressure to form continuous convolutions. Available with 2 to convolutions for all nominal widths. Design: Pure PTFE bellows with external stainless steel support rings, PTFE profiles on both sides with steel backing flange and integral restraint. Pressure and vacuum diagram with temperature influence Flange: Material GGG with rust preventive coating (hole circle drilling partly with threaded holes, for narrow design), standard design PN. Special holes and materials available on request. 2 Conv. Overall length 3 Conv. + je Conv.* Movement absorption with 2 convolutions ax + lat + ang + Movement absorption with 3 convolutions ax + lat + ang + Movement absorption per further convolution* ax + lat + ang *max. Convolutions flange picture see page. To order or get further details, call your local contact shown on rear cover or listed at

48 James Walker Townson Rubber Comflex Expansion Joints Tie Bars Restraints Under pressure, rubber expansion joints develop a reaction force in the positive axial direction (effective surface x working pressure) which for unrestrained expansion joints Design A must be absorbed by the nearest anchor points or roller bearings. When used for the absorption of vibrations, lateral and angular expansion as well as noise, it is possible by the arrangement of restraints to create a controlled installation situation (controlled expansion absorption, see installation information). Our BM limiter types can be used for all types (except H only for type 9). The diagrams show the various types. Example of the application of a flange design as a universal joint 0 (design G) Flange shapes for tie bars as per designs BE ( bar) (00) 00 Design A Rubber expansion joint without restraint with swivel flanges, suitable for allround movement absorption. Design B Rubber expansion joint with tie bar for the absorption of reaction force. Tierods fitted in rubber bushes. Suitable for absorbing noise, vibrations and lateral (radial) movement (± ). Design C Rubber expansion joint with tie bar for absorption of reaction force. Tierods fitted in rubber bushes including thrust limiters for bellows retention. Suitable for absorbing noise, vibrations and lateral (radial) movement (± ). To order or get further details, call your local contact shown on rear cover or listed at

49 Design E Rubber expansion joint with tie bar for absorbing the reaction force. Tierods are fitted with cshaped washer and ball disc. Suitable for lateral movement (radial). Design F Rubber expansion joint with hinged arrangement for absorbing the reaction force. Suitable for angular movement in one plane; two hinged expansion joints with an intermediate pipe can absorb very large lateral movements (see installation examples). Design G Rubber expansion joint with universal restraint for absorbing the reaction force. Suitable for absorbing angular movement in a circular plane. Three universal joints in an angular arrangement can absorb very large axial and lateral movement (see installation examples). Design L Rubber expansion joints with segment restraint supported in spherical discsconical sockets for absorbing thrust and tensile forces. Suitable for absorbing lateral movement in pressurised and vacuum applications. Design K Rubber expansion joint with external tie bars fitted with cshaped washer for absorbing the reaction forces. Suitable for absorbing large lateral (radial) expansion. Design H Rubber expansion joint with external tierod restraint for absorbing the reaction force. External tierods are supported in spherical discs and ball cups with internal hexagon nuts for thrust limitation. Design M Rubber expansion joint with internal restraint and tie rods supported in spherical discsconical sockets for absorbing thrust and tensile forces. Suitable for absorbing lateral movement in pressurised and vacuum applications. Note: In normal cases, the design of the restraints is based on the reactionfriction force. Please contact us should additional pipe forces need to be absorbed! To order or get further details, call your local contact 9 shown on rear cover or listed at 9

50 Special Parts Flameproof protective covers s, 9,, 55 are available in asbestosfree design approved by the Classification Society. These accessories protect the rubber expansion joint against the effects of flames up to 00 C for a period of minutes. James Walker Townson Comflex Expansion Joints together with their flameproof protective covers satisfy the requirements of the Classification Society for use on ships, for fire extinguishing piping in operational buildings or in pressure booster plants. Installation information: The expansion joints are installed in the usual manner. The protective covers are fitted after installation and cover both the expansion joint and adjacent pipe flange. Operation of James Walker Townson expansion joints is not hindered as the cover extends to the pipe, the full movement of the expansion joint can be absorbed. Special cover and restraint sizes are available on request. Diagram shows open condition. Deflector sleeve This should always be used for highly abrasive media or if strong turbulence is to be avoided. The deflector sleeve is made in conical form with edge flangeholed flange, so that the expansion capabilities of the expansion joint are least affected. The deflector sleeve length depends on the length of the expansion joint and the movement to be absorbed (standard value: expansion joint length corresponds to the deflector sleeve length). Installation information: Gaskets must be fitted. Gap between the buildings should be arranged according to the deflector. Attention: In the case of axial expansion in excess of, the mating flange inside diameter must be taken into account and the deflector sleeve diameter checked. With lateral expansion, the deflector sleeve diameter reduces by twice the lateral movement to be absorbed (standard design for lat. +5). To order or get further details, call your local contact shown on rear cover or listed at

51 Special Parts Earth Cover Available for all types with or without tie bar. The earth cover is a two piece cover, which is especially designed to protect rubber expansion joints in the earth. It is designed not to limit expansion joint movement. Design: Twopiece cover of S 2 JR G2 (RSt 32) or stainless steel. Fixing takes place with clamps which are permanently joined to the halves of the covers. Note: Easy installation, due to twopiece design. It must be ensured during installation that downward drainage is possible. Safety expansion joint Available for all types with or without tie bar. The safety expansion joint is used for aggressive media for the purpose of leakage monitoring (2bellows system). Pressure balanced expansion joint Available for all types. The pressure balanced expansion joint absorbs the reaction forces within the restraint and is suitable for absorbing axial and lateral movement. To order or get further details, call your local contact 51 shown on rear cover or listed at 51

52 Planning, Installation and Maintenance Instructions for 39, 5,,, 9,, 51, 53, 5, 55, 5 and 5 James Walker Townson rubber Comflex Expansion Joints are supplied ready for installation and are fitted with onepiece rotary metal flanges in conformity with the standard connection (DIN, ASA, BS, etc.). The flanges should fit neatly, without any burr, within the clamping range of the rubber bellows with a rubber sealing surface protruding about 2, depending on the nominal width. Planning instructions The lines must be designed in such a manner that the expansion joints are guided by fixed bearings (FP) or sliding bearings (GL); see: Installation example 1 Compensating of axial expansion with unbraced expansion joints. Installation example 2 Compensating lateral and axial expansion with an unbraced expansion joint. Installation example 3 Compensating of lateral and axial expansion with unbraced expansion joints at an outgoing pipe. Installation example Compensating of axial expansion by angular movement reversal with braced expansion joints. Advantage: Large axial expansions can only be absorbed by two expansion joints. Installation example 5 Arrangement of pipe hinge expansion joints in three hinge systems for absorbing expansion in two directions. Advantage: High expansion absorbing rates, low adjusting forces, a soft corner. Installation example Use of rubber expansion joints with pumps. In this case expansion joints in the pressure line should always be braced to ensure that internal pressure does not overload the pump connecting piece. A vacuum bearing ring should be used on the suction side if the negative pressure exceeds 0. bar, absolute. Bracing examples: Rubber expansion joints must be installed between fixed points, as described above, in order to take up axial expansion. The axial and lateral expansion must be transformed where this is not possible so that braced rubber expansion joints can be used to neutralize the arising reaction forces (inside surface of the expansion joint multiplied by the operating pressure). In this arrangement only appropriate sliding bearings can be used for correct introduction of the expansion. IMPORTANT When conveying abrasive media (liquids containing solids, e.g. watersand) the expansion joints must not be directly attached to the pump connecting piece (suctionpressure side), due to a risk of the expansion joints being damaged by the relatively high speeds associated with the twist and whirl formations in the pump connecting piece. This also applies to bent pipes and tailings. EB The installation space between the pump connecting piece and expansion joint must be 1 to 1.5 times the nominal diameter (). Pump operation against a totally or partially closed gate or flap valve must be avoided. Cavitation must also be avoided as this can result in the rapid destruction of the expansion joint. EB (Axial prestress) With axial prestress it is necessary to ensure that the expansion joints are prestressed by not more than maximum when in a noninstalled state. For higher prestresses an expansion joint in conformity with EB must be used, i.e. the expansion joint must be first fully installed after which the corresponding prestress is generated with the firmly installed expansion joint. Reason: With a higher prestress in a noninstalled state, the sealing bead can spring out of the holder of the steel backing flange and damage the sealing bead in the process. EB (Lateral prestress) For expansion joint arrangement, it must be ensured when dimensioning the pipe that any necessary lateral prestress must be applied only with a securely installed expansion joint by means of pipe misalignment (EB a). A lateral prestress of only 5 is possible prior to installation. It must however be ensured that the rubber bead is not pulled out of the groove in the steel backing flange. Safety measures The pipes must be protected against impermissible overpressure, excessive rise of temperature and uncontrolled vacuum. The limiting values for the respective settings are shown in the data sheets of our catalogue relating to the respective types. In addition, appropriate drain and venting options should be provided to prevent water impact and vacuum failures, which can also cause expansion joint damage. An extensive range of rubber expansion joint bracings is listed in our catalogue. 52 To order or get further details, call your local contact shown on rear cover or listed at

53 Media safety Since the inside of the expansion joint comes into contact with the media, it must be ensured that only media is pumped as specified in the resistance list as suitable for the inner rubber. If other media are used we should be notified of the same together with the relevant data in accordance with the safety data sheet for chemical substances and preparation, in order that we may ascertain whether the inner rubber of the expansion joint is suitable. Flow rates With high flow rates it is necessary to clarify whether the expansion joints have to be installed with or without a guiding pipe to avoid wear as a result of excessive whirling. Mating flanges Mating flanges must conform in their design with EB 9 to ensure reliable sealing and clamping of the rubber expansion joints. Installation 1. Check the packaging of the rubber expansion joints for damage. Damaged expansion joints must never be released for installation. 2. Check the envisaged installation gap. The mating flange must be installed in true alignment. The maximum deviation within the installation gap in relation to the expansion joint is +, minus the corresponding expansion specifications. The maximum lateral deviation of the flange is 5. Note: If it is not possible to observe the above tolerances then proceed with an axiallateral prestress as defined by EB EB a. 3. Arrangement of the screws EB For expansion joints that have throughholes the screw heads must face the bellows to avoid damaging the bellows body when under pressure. For expansion joints with threaded holes in the flange, the screws must fit flush with the inner side of the flange in relation to the bellows so that protruding screws cannot damage the bellows when under pressure.. The flange screws must be evenly tightened in alternation as shown in Table 1. It must also be ensured that the sealing bead does not tilt. The entire protruding sealing surface must be uniformly compressed. The screws must be evenly tightened crosswise 3 times. 5. Tightening with a torque wrench Evenly tighten all screws manually (stage 1) (ensure parallelism with the sealing surfaces). The tightening torques specified in Table 1 are sufficient for an operating pressure of 1 bar. These values should be increased by % for an operating pressure of bar. After the third stage, minutes should be allowed to pass before retightening to the final torque specified in stage 3. Further tightening of the screws is unnecessary, particularly since this could destroy the surface seal. Table 1 Stage 3 Stage 2 1 bar bar 0 Nm 0 Nm 0 Nm 0 0 Nm 0 Nm 10 Nm 0 Nm 1 Nm 1 Nm 00 0 Nm 2 Nm 20 Nm 0 0 Nm Nm 3 Nm 0 Nm 20 Nm 3 Nm 00 0 Nm 0 Nm 0 Nm Nm 3 Nm Nm 00 0 Nm 3 Nm Nm Attention: Bellows Bellows must not be painted or insulated. Pressure test The rubber expansion joint is not a proper pressure vessel, but is classified according to the Pressure Equipment Directive as a pipe accessory (pipe component). When including the expansion joint in the pipeline, sealing does not take place via a separate seal, but directly on the integrated surface seal of the rubber bellows. A one hundred per cent pressure test of the rubber expansion joints at the manufacturer can adversely influence the integrated rubber sealing surface. For this reason, pressure testing of the rubber expansion joints at the manufacturer takes place only at the special request of the customer with the utmost care. The pressure test is normally carried out only after the rubber expansion joints have been fully installed in the pipeline system. The information contained in these installation instructions should be observed prior to the pressure test. To order or get further details, call your local contact 53 shown on rear cover or listed at 53

54 Advice 1. After the expansion joints have been installed they should be protected in an appropriate manner against damage, and the protection should only be removed just before putting into operation. 2. Cover the rubber bellows when carrying out welding and torchcutting work; temperatures in excess of 0 C can cause damage. 3. The rubber parts must not be overpainted. Solvents and chemicals will attack the surface and destroy the bellows.. The expansion joints must not be insulated as this can result in overheating and drying the bellows and damage to the same. 5. The best operating results are achieved when the expansion joint operates stressfree under operating conditions (take appropriate prestressing into account during installation).. The fixed points must be checked to see whether they are suitable for absorbing the reaction force from the nonbraced expansion joint or whether the adjusting forces and initiation of expansion with appropriate sliding bearings take place at the correct distance from the expansion joint.. Expansion joints braced with tie rods should be appropriately adjusted following installation. The tie rods should be able to be turned handtight. All hexagon nuts must subsequently be locked with lock nuts. Maintenance 1. Rubber expansion joints do not require any maintenance, but they must be regarded as wearing parts. 2. It is important that the installed parts are regularly inspected for initial signs of ageing, leakage and blister formation. In the event of major maintenance work on the plant, the condition of the interior lining should also be inspected (e.g. check for swelling, hardening, washout and cracks). Storage room The storage room must be cool, dry, dustfree and moderately ventilated. Oxygen and ozone Rubber parts must be protected from draughts. If necessary they should be covered. Do not operate any ozonegenerating facilities in the storage room, e.g. electric motors, fluorescent lamps, etc. Other jointly stored media Do not store solvents, fuels, chemicals or similar substances in the same storage room. Supplementary installation and mounting instructions for type 5 (EB 11) The type rubber expansion joint should be installed free of any tension. Screws should always be tightened with two wrenches to avoid damaging torsions being transmitted to the expansion joint; see EB 11. Installation procedure 1. Attach the screwjoining parts to the pipe and check the installation gap! The installation gap must equal the expansion joint length (1 +5). 2. Insert the expansion joint and tighten with two wrenches. Nominal diameters The front screwin part is used as a steady while the union nut is tightened (to avoid the transmission of torsions to the bellows). Nominal diameters The rear screwin part is used as a steady while the union nut is tightened (to avoid the transmission of torsion to the bellows). See main installation instructions for all other installation points. Storage See DIN 1 Rubber products Requirements for storage, cleaning and maintenance: Rubber expansion joints must be stored free of stress, deformation and bending. Rubber expansion joints with steel flanges must be stored upright on the flanges (to avoid the risk of crushing). 5 To order or get further details, call your local contact shown on rear cover or listed at

55 Installation Examples EB 1 EB EB 2 EB EB 3 EB EB EB 5 EB a To order or get further details, call your local contact 55 shown on rear cover or listed at 55

56 EB 9 EB EB 11 5 To order or get further details, call your local contact shown on rear cover or listed at

57 Installation and Maintenance for all Solid Rubber Flanges for s, 2, 5, 59, 3 Extract from documentation required by the Technical Inspectorate for type large expansion joints (cooling water system in a nuclear power station). 1. Identification 1.1 Delivery documentation and expansion joint identification marking must correspond. 1.2 Identification marking on the rubber expansion joint a) On the expansion joint collar, above the embossed name plate. XX XXXX Production No. monthyear b) Name plate James Walker Townson expansion joint made by Continental xxx xxx bar Materialinserts working operating pressure xxxxxx Nominal widthflange build length xxx Standard build length* * Attention: The installation length (mounting) can vary! Check prerestraint! 3. Storage (see DIN 1) Guidelines for the storage of rubber parts Rubber expansion joint must be stored stressfree without deformations and kinks. Rubber expansion joints must be stored upright on the flanges (to avoid the risk of crushing!). 3.1 Storage room The storage room should be cool, dry and dustfree and moderately ventilated. 3.2 Oxygen and ozone Protect rubber parts from draughts, cover in case of emergency. Do not operate ozoneproducing devices such as electric motors, fluorescent light sources etc. in the store room. 3.3 Costorage Do not store with solvents, fuels, chemicals and similar items. 2. Transport 2.1 Packaging Package parts. Note TOP at the top and cable or lifting hook steel backing rings (with bracing) and the rubber expansion joint flanges must remain fastened until final mounting. The relatively light rubber part is bonded to heavy metal flanges avoid excessive loading of the rubber part. 2.2 Tools No sharpedged tools, wire cables, chains or lifting hooks (danger of damage to rubber). 2.3 Lifting and moving Always lift both steel flanges simultaneously. Shackle at both sides or place padded tiebars through the expansion joint or lift both sides. 2. Ground level transportation Move flanges by rolling.. Installation.1 Pipes.1.1 Check dimensions of planned installation gaps. The total installation discrepancies in the piping and operating movements must not exceed the maximum movements specified in the design layout..1.2 Clean mating flanges, remove anticorrosion paint from surfaces..1.3 Mating flanges must be smooth, flat and free from burrs..1. Do not subject the expansion joint to stress. Bolt holes must be in alignment..2 Bellows The bellows must not be painted or insulated. To order or get further details, call your local contact 5 shown on rear cover or listed at 5

58 .3 Installation.3.1 Do not use sharpedged tools. Additional gaskets are not required. The expansion joint rubber flange seals directly on to the pipe flange..3.1 Fasten the expansion joint at both flanges with e.g. 2 threaded rods before loosening the lifting device..3.2 Insert all flange bolts and handtighten..3. Do not use plain washers on steel backing flanges..3.5 If at all possible, do not position bolt heads against the expansion joint bellows... Tighten flange bolts crosswise using a torque wrench with the specified torque over 3 intervals... Do not weld close to the rubber expansion joint. If necessary, cover the expansion joint with asbestos for protection against welding heat and flying sparks (sparks and temperatures above 0 C will damage the rubber parts!). Attention: When welding, steelwire expansion joints throughout the whole piping system can be damaged by current leakage or electrical earthing. The anode and cathode of the E welding connection must always be on the same section of piping. (Not separated by the rubber expansion joint!). The bellows must not be painted or insulated. 5. Pipe leading 5.1 Anchor points and mountings Prior to filling the piping, it must be ensured that all anchor points and mountings are installed and operational. The bracing anchors must provide uniform support and must be adjusted to the existing piping.. Final installation inspection.1 Damage Check complete expansion joints for visible damage and in particular clean the gap between the steel backing flange and rubber bellows (remove foreign bodies, sand, etc.)..2 Leakages Tighten bolts when possible leakages occur during pressure testing (1.3 x design pressure).. Maintenance and Monitoring.1 Before final coissioning, check the tightening torque of the flanged joints..2 Rubber parts must not be painted and should be kept clean. (Clean with water or soapy water). Keep the parts free from grease and oil..3 Inspection must be carried out minimum one week after coissioning. Tighten flange bolts with torque wrench. Inspections must be carried out after 1, and months, then annually.. Inspection criteria External damage to rubber and bracing. Deformation of rubber flange external diameter between the bolts (flange surface displacement). Variations in the rubber bellows (blister formation, brittleness, fissures, hairline cracks) Check bracing for excessive movement and misalignment. Assess corrosion and wear over the whole component. 5 To order or get further details, call your local contact shown on rear cover or listed at

59 Flange Bolt Torque (Nm) for James Walker Townson Comflex Expansion Joints for s, 2, 5, 59, 3 Installation information Tools: Torquewrench, rubber haer, centre punches. All tools to be burrfree (danger of damage to rubber parts) Use flange bolts with property class. (new bolts, greased). Step l a) insert all bolts and tighten equally by hand. b) Fasten with about 3 crosswise and uniform turns at torque Nm ( kpm). Check gap width at outer edge of flange. c) Settling time minutes. Step II d) Tighten all bolts crosswise by 3 turns as per table above or 23 of final torque. Check gap width. e) Settling time > 0 minutes. Step III f) Tighten crosswise 2 turns at final torque. DO NOT TIGHTEN FURTHER! Before test pressure: check torque 1 turn crosswise with final value (Step III). Later inspections: follow service manual. Only tighten flange bolts to final value (Step lll). Flange tightening torque The flange bolt torques given in the table provide a specific surface pressure of N2 relative to the total surface of the expansion joint flange (use flanges without seal). Because of the temporary settling process in the rubber flange area the surface pressure falls under working conditions to some % of the final value (step III). The residual effective gripping and sealing force is completely sufficient and suitable for test pressures up to 1 bar (tensile stresses from overexpansion are not permissible!). Attention: Torque: The maximum tightening torques given must not be substantially exceeded, since an excessive load causes a constant increase in the flow in elastomer and leads to destruction (crushing). Rough estimation of the final tightening torque for special flanges Rule of thumb M A = 0.2 F VM d 2 M A = Bolt Tightening Torque d2 = Screw Thread FlanksO F VM = Installation Prestress Force = K A * F KL *KA = Tightening Factor ~ 1. greased, against a firm support KA = Experimental Value = 1.0 selected flow process in rubber flange FKL = Clamping Force, Contact Pressure N 2 for total flange surface for F KL = ( Flange D 2 2 ) x π x Contact Pressure x (N) Number of bolts To order or get further details, call your local contact 59 shown on rear cover or listed at 59

60 Step I Step II Step III Preassembly PN PN PN 1 ASA 0 PN PN PN 1 ASA 0 Nm Nm Nm Nm Nm Nm Nm Nm Nm < on request 0 To order or get further details, call your local contact shown on rear cover or listed at

61 Installation and Maintenance Information for Storage The expansion joints should be stored under clean and dry conditions and must be protected against mechanical damage. Do not unpack the expansion joint until ready for installation. Protective covers should be left on as long as possible. Transportation support devices must not be removed until the expansion joint is in position in the pipeline system. Installation Do not start installation until all work on the ducting and flanges has been completed and all anchors and supports have been fitted. This serves to prevent any damage to the expansion joint through welding sparks, sharp objects etc. and ensure that the expansion joint is not overstressed. The bellows must not be painted or insulated. The expansion joints are manufactured from highly flexible materials. The durability depends on careful and correct installation. Sharp edges and folds must be avoided and care must be taken when lifting expansion joints during installation. It is recoended to use a supporting plate or an internal frame for lifting purposes. Preferably, a expansion joint should be preassembled with backing flanges and internal sleeve (if included in the delivery) on the ground before lifting. Ducting flanges tolerances If the delivery includes ducting flanges, backing flanges or other steel parts, check that the measurements correspond with the drawings and that bolt holes are arranged syetrical in each flange. The bolts must be retightened 2 hours after installation of the expansion joint. Plates for the assembly of expansion joints with welding flanges. Bolt torque Backing flanges bolts x M x M 0 x M 0 x M1 NBR 0 Nm Nm 0 Nm 0 Nm 0 Nm 0 Nm 0 Nm 0 Nm VITON 0 Nm 0 Nm 0 Nm Spacer for Install Rubber Expansion Joints with Slipon Flanges A B A B A B A B A B A B A B A B A B A B A B A B To order or get further details, call your local contact 1 shown on rear cover or listed at 1

62 Installation Instructions for 0 1. Protective covers These serve to protect the beading sealing surface against mechanical damage and must only be removed directly prior to assembly. If removal for the purpose of inspection is necessary, the protective covers must subsequently be bolted tight. 2. Welding, soldering and brazing on the lined components is not permitted as this can damage the highquality lining and give rise to the release of highly toxic gases. 3. The use of seals between PTFEPTFE sealing faces is unnecessary. For connections to glass, ceramics, enamel and other components, an approximately 5 thick PTFE seal is recoended.. Installation To prevent deformation of the sealing faces through overtightened bolts, the following torques should be referred to as a guide during assembly. (The values apply to flanged joints up to PN for bolts with lubricated thread.) 5. Painting Insulation The expansion joint bellows must not be insulated or painted. Splash protection covers must be fitted so that heat accumulation in the area of the bellows is avoided through heat transmission.. Coissioning After reaching operating temperature, the flange connections should be retightened with the specified torque. In case of leakages, the flange connections must be checked for parallelism or soiling or damage of the sealing face. Minor indentations or damage can be removed with emery cloth.. Installation of expansion joints In additon to the aforementioned, the tie rods must not be removed after adjustment to maximum expansion or after installation. The bellows must not be painted or insulated. Flange connection dimensions according to DIN 1 PN PN Quantity Screws Thread Md NM Quantity Screws Thread Md NM M M M 1 M 1 M 1 M 1 M 1 M 1 M 1 M M M M M M 2 M 2 M 2 M M M M 1 M 1 M 1 M 1 M 1 M M 2 M 2 M 2 M To order or get further details, call your local contact shown on rear cover or listed at

63 Sealing Profile of the Rubber Bellows Design E Design S 9 C B 55 ± 2 ± 2 ~ AD C 1 B 1 53 ± 2 ± 2 ~ AD C 3 B 3 9 ± 2 ± 2 ~ A 3 AD C 2 B 2 39 ± ± ~ A 2 AD A A To order or get further details, call your local contact 3 shown on rear cover or listed at 3

64 To order or get further details, call your local contact shown on rear cover or listed at Mating Flange Dimensions ød øpc n ød Thread. d M M M M M M1 M1 M1 M1 M1 M1 M1 M M M M M M2 M2 M2 M2 M2 M M M33 M33 M33 M33 M3 M3 M39 M39 M39 M39 M39 ød øpc n ød Thread d M M1 M1 M1 M1 M1 M1 M1 M M M M M M M2 M2 M2 M2 M2 M M M33 M33 M3 M39 M39 M5 M5 M5 M5 M5 M5 M52 M52 M52 ød ø pc n ød Thread d M M1 M1 M1 M1 M1 M1 M1 M M M M2 M2 M2 M2 M2 M M33 M33 M3 M3 M39 M5 M5 M5 M5 M52 M52 M52 M52 M5 M5 M5 M5 ød øpc n ød Thread d M1 M1 M1 M1 M M2 M2 M2 M2 M2 M2 M M33 M33 M3 M39 M5 M5 M52 M5 M5 M5 M M ød ø pc n ød Thread d inch PN PN PN 1 PN ASA 0 lb.

65 Additional Comflex Expansion Joints Comflex Gas Turbine Exhaust Expansion Joints Finite Element calculations available for frame designs References for the most difficult turbine applications Turnkey package offered for design, supply and installation Joints available for high cyclic life requirements and extended warranties. Comflex Flue Duct Joints Available as multilayered fabrics for temperature applications to C Viton and joints of any size available for wet and chemical applications Elastomeric fan outlet joints available with extended warranties All joints can be supplied open ended with installation and joining kits for site assembly Frequently supplied assembled on a frame for ease of fitting as a cartridge. Comflex Metallic Expansion Joints Circular or rectangular crosssection Complete range available or designed to customer requirements Full design service and onsite technical support. Service Service contracts available to provide maintenance cover for your expansion joints Turnkey package of design. supply and installation frequently provided Thermographic surveys and technical reports provided to ensure constant monitoring of the condition of your joints On site technical support and consultation provided to address troublesome applications. To order or get further details, call your local contact 5 shown on rear cover or listed at 5

66 Technical guides and data sheets These guides give detailed technical information on some of the products and services supplied by James Walker. Please ask for your copies, or visit our website where many of them can be downloaded in pdf form. Sealing Guide for Conventional Thermal Power Generation Global supply of Bestvalue fluid seals & gaskets Standard & customdesigned products Expansion joints & bellows Bolting technology Vibration damping & control James Walker s comprehensive guide to quality gasket products for industry worldwide High Performance Sealing Technology Sealing Guide for Conventional Thermal Power Generation Gaskets & Jointings Guide High Performance Sealing for the Hydropower industry Environmental emissions control Global supply of sealing products for: Francis & Kaplan turbine shafts Kaplan blade roots & wicket gates Inlet valves, dam gates & fish screens Servo motors & jacks Pelton turbine injectors How James Walker can help your business A guide to effective sealing systems from the James Walker Group High Performance Sealing Technology Hydropower Industry Guide Environmental Emissions Guide To order or get further details, call your local contact shown on rear cover or listed at

67 Technical guides and data sheets Trademark acknowledgements James Walker acknowledges the following trademarks as mentioned in this document. All other names bearing the symbol are registered trademarks of James Walker. Trademark Hypalon Kevlar Nomex Viton Company DuPont Performance Elastomers DuPont DuPont DuPont Performance Elastomers Health warning: If PTFE or fluoroelastomer (eg, FKM, FFKM, FEPM) products are heated to elevated temperatures, fumes will be produced which may give unpleasant effects, if inhaled. Whilst some fumes are emitted below C from fluoroelastomers or below 0 C from PTFE, the effect at these temperatures is negligible. Care should be taken to avoid contaminating tobacco with particles of PTFE or fluoroelastomer, or with PTFE dispersion, which may remain on hands or clothing. Material Safety Data Sheets (MSDS) are available on request. Information in this publication and otherwise supplied to users is based on our general experience and is given in good faith, but because of factors which are outside our knowledge and control and affect the use of products, no warranty is given or is to be implied with respect to such information. Specifications are subject to change without notice. Statements of operating limits quoted in this publication are not an indication that these values can be applied simultaneously. Intelligent tension control... Comflex Expansion Joints and Bellows Tension control at your fingertips High Performance Expansion Joint Technology Rotabolt Intelligent Tension Control Comflex Expansion Joints and Bellows To order or get further details, call your local contact shown on rear cover or listed at

68 James Walker companies worldwide James Walker & Co Tel: + (0) Fax: + (0) csc@jameswalker.biz James Walker Australia Tel: +1 (0) Fax: +1 (0) sales.au@jameswalker.biz James Walker Benelux (Belgium) Tel: Fax: sales.be@jameswalker.biz (Netherlands) Tel: +31 (0) Fax: +31 (0) sales.nl@jameswalker.biz James Walker China Tel: Fax: sales.cn@jameswalker.biz James Walker Deutschland Tel: +9 (0) 3 0 Fax: +9 (0) 39 sales.de@jameswalker.biz James Walker France Tel: +33 (0)3 9 Fax: +33 (0) sales.fr@jameswalker.biz James Walker Iberica Tel: Fax: sales.es@jameswalker.biz James Walker Ireland Tel: +3 (0)21 Fax: +3 (0) sales.ie@jameswalker.biz James Walker Italiana Tel: Fax: sales.it@jameswalker.biz James Walker Mfg (USA) Tel: +1 5 Fax: sales.jwmfg.us@jameswalker.biz James Walker New Zealand Tel: + (0) Fax: + (0) sales.nz@jameswalker.biz James Walker Norge Tel: + 00 Fax: sales.no@jameswalker.biz James Walker Oil & Gas (USA) Tel: Fax: oilandgas@jameswalker.biz James Walker Singapore Tel: Fax: sales.sg@jameswalker.biz James Walker South Africa Tel: +2 (0) Fax: +2 (0) sales.za@jameswalker.biz James Walker Townson Ltd Alexandra Street, Hyde Cheshire SK1 1DY, UK Tel: + (0) Fax: + (0) sales.townson.uk@jameswalker.biz C0201 BP 92m CPN0003 Registered Office: James Walker Townson, Alexandra Street, Hyde, Cheshire, SK1 1DY. United Kingdom. Reg No England James Walker 09